Integral Volume Booster End Cap for Simpler Pneumatic Actuators

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Solution Overview

Problem

The installation and maintenance of pneumatic actuator systems with volume boosters are complex and costly due to the need for multiple tubes, fittings, and air connections, which complicates configuration and increases expenses.

Innovation Solution

Additive manufacturing is used to create endcaps with integrated volume booster components, eliminating the need for excess air tubes and fittings by forming the main body and air passageways within the endcap, allowing for modular installation and efficient maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional volume booster systems are used with multiple tubes and fittings, then the pneumatic actuator can be assembled, but the device complexity and installation cost increase significantly

Engineering Contradiction:

Improvepneumatic actuator functionalityVSAvoidnumber of tubes and fittings

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The end cap integrates multiple previously separate components (volume booster body, tubes, fittings, air passageways) into a single additively manufactured part. The main body includes internally formed fluid passageways that replace external tubing, and the volume booster is merged with the end cap structure, eliminating the need for separate tube connections and reducing assembly complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated end cap performs multiple functions simultaneously: it serves as the structural end closure, contains the volume booster mechanism, provides fluid distribution pathways, and incorporates mounting features. This multi-functionality reduces the total component count while maintaining all necessary pneumatic actuator functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If traditional volume booster systems with multiple components are used, then the pneumatic actuator can be assembled, but the manufacturing cost increases due to excess materials and assembly requirements

Engineering Contradiction:

Improvepneumatic actuator functionalityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention utilizes additive manufacturing technology to change the production method from traditional subtractive manufacturing or assembly of multiple parts. This manufacturing parameter change enables complex internal geometries and integrated structures that would be costly or impossible to produce with conventional methods, thereby reducing overall manufacturing cost despite the complexity of the integrated design.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If traditional volume booster systems are used, then the pneumatic actuator can be assembled, but the overall system weight increases due to excess materials

Engineering Contradiction:

Improvepneumatic actuator functionalityVSAvoidend cap assembly weight

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates unnecessary excess materials (separate tubes, fittings, and redundant structural elements) by integrating their functions directly into the end cap. The additively manufactured structure achieves the required strength and functionality with optimized material distribution, removing weight from the system while maintaining pneumatic actuator performance.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If traditional volume booster systems are used, then the pneumatic actuator can be assembled, but the installation and maintenance time increases due to complex configuration

Engineering Contradiction:

Improvepneumatic actuator functionalityVSAvoidinstallation and maintenance time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The end cap is pre-integrated with the volume booster and internal fluid passageways during manufacturing, so that during installation, the entire assembly is installed as a single unit rather than assembling multiple separate components on-site. This preliminary integration of complex features eliminates time-consuming field assembly operations and reduces installation time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention segments the pneumatic actuator into modular components (cylinder, piston, and integrated end cap assembly with volume booster) that can be independently manufactured and then quickly assembled. This modular segmentation allows for rapid installation by simply coupling the pre-assembled end cap to the cylinder, reducing overall installation time while maintaining system functionality.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11635098B2Pneumatic actuator end cap having an integral volume booster

Publication Date: 2023.04.25 FISHER CONTROLS INT LLC

AI summary

Methods, apparatus, systems and articles of manufacture are disclosed that produce a pneumatic actuator end cap having an integral volume booster. An example pneumatic actuator end cap includes a first cavity to provide a first fluid passageway to receive a pressurized fluid from a source external to the pneumatic actuator end cap, a second cavity to provide a second fluid passageway to route the pressurized fluid to an internal chamber of a pneumatic actuator in which a piston is disposed, and a third cavity containing a fluid valve to control a flow of the pressurized fluid between the first fluid passageway and the second fluid passageway.